Pin-Actuated Printhead for High Viscosity Ejection
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Solution Overview
Problem
Current additive manufacturing processes, such as inkjet printheads, are limited to materials with viscosities up to 20 centipoise, while methods like FDM and SLS cannot create multi-material composites or intermix materials effectively, leading to a demand for processes capable of handling high viscosity materials for multi-material or multi-color composites.
Innovation Solution
A pin-actuated printhead is designed to eject materials with viscosities of 10,000 cP or more at elevated temperatures, featuring actuated pins that control material ejection through orifices, with chambers under pressure and actuator modules for precise material handling, allowing for the use of high viscosity engineering polymers and other materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional inkjet printheads are used, then low viscosity materials (up to 20 cP) can be deposited, but high viscosity materials (10,000 cP or more) cannot be ejected
Solution Approach 1:
The patent changes the physical parameters of the ejection mechanism by replacing conventional inkjet droplet ejection with pin-actuated mechanical ejection. The pin enters the orifice to directly push material out, changing the ejection mechanism from fluid-dynamic to mechanical contact, enabling high viscosity materials to be ejected effectively
Solution Approach 2:
The patent substitutes the conventional inkjet mechanical system with a pin-actuated system. Instead of using piezoelectric or thermal actuators to create pressure waves for droplet ejection, a physical pin mechanically enters and pushes the material through the orifice, providing direct mechanical force capable of moving high viscosity materials
2Quantity of substance
If FDM or SLS methods are used, then extremely viscous materials can be processed, but multi-material composites or intermixing of deposited materials cannot be achieved
Solution Approach 1:
The patent segments the material delivery system into multiple independent chambers, each capable of holding different materials. Each chamber has its own pin actuator and orifice, allowing independent control and ejection of different materials. This segmentation enables multi-material composite printing while maintaining the mechanical ejection capability for high viscosity materials
Solution Approach 2:
The patent implements dynamic control of multiple pins and chambers, where each pin can be actuated independently at different times and with different forces. This dynamic control allows for sequential ejection of different materials, creating multi-material composites and enabling intermixing patterns that static systems cannot achieve
3Quantity of substance
If actuated pins are used to eject high viscosity material, then material ejection is achieved, but precise control of ejection volume and timing is required
Solution Approach 1:
The patent incorporates feedback control mechanisms where the actuation of each pin is precisely controlled based on timing signals and position feedback. The system monitors and adjusts the ejection timing and duration to ensure consistent material volume delivery, achieving manufacturing precision despite the complexity of mechanical pin actuation
Data Source
AI summary
A pin actuated printhead includes an orifice through which a material is ejected, a chamber to hold the material to be ejected, a channel connecting the chamber to the orifice, and an actuated pin, to enter the orifice and to eject the material from the orifice. The printhead is configured to eject a material with a viscosity of 10,000 cP or more at an elevated temperature.